Thermomechanical process modelling and simulation for additive manufacturing of nanoparticle dispersed Inconel 718 alloys

IF 1.9 4区工程技术 Q3 MECHANICS

Continuum Mechanics and Thermodynamics Pub Date : 2024-12-06 DOI:10.1007/s00161-024-01346-9

E. Yousefimiab, A. Kendibilir, Y. Yalcin, C. Cardillo, E. Aydogan, A. Kefal

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引用次数: 0

Abstract

In this study, a coupled transient thermomechanical finite element model is developed to examine the laser powder bed fusion (L-PBF) process of the Inconel 718 (IN718) and Oxide Dispersion Strengthened (ODS) superalloys (ODS-IN718). The linear isotropic elastic perfectly plastic constitutive model is implemented for the mechanical part whereas all the thermophysical properties are defined as fully temperature dependent. This new model enables three states of the metal including powder, liquid, and solid phases in the continuum-based finite element simulations. Besides, it can meticulously simulate multi-layered samples to assess thermomechanical performance and residual stress between layers. First, benchmark problems are revisited to verify the high accuracy of the present model for predicting transient temperature profile and residual stress accumulation. Then, thermomechanical analysis of a single-track three-layer test case is performed to investigate the L-PBF process of IN718 and ODS-IN718 samples for various laser powers and scan speeds. Also, the thermal characterization of ODS-IN718 samples is experimentally conducted. It is demonstrated that the numerical melt pool dimensions provide good agreement with experiments with an average error of 17% for melt pool dimensions. Moreover, mechanical results reveal that high tensile residual stresses accumulate in the middle part of the track. The manufacturing quality of the IN718 and ODS-IN718 samples are comprehensively compared based on the variations of stress distribution at different layers for different laser scan speeds. Also, the optimal laser scan speed is achieved to minimize the residual stresses for the ODS-IN718 alloy. Overall, ODS-IN718 has a lower residual stress than IN718 especially at lower laser scan speeds due to the enhanced thermomechanical behavior attributed to the change in material properties due to the presence of dispersed particles.

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纳米颗粒分散Inconel 718合金增材制造的热力学过程建模与仿真

本文建立了瞬态热-力学耦合有限元模型，研究了Inconel 718 （IN718）和ODS-IN718 （ODS-IN718）高温合金的激光粉末床熔合过程。力学部分采用线性各向同性弹性完美塑性本构模型，所有热物理性能均定义为完全依赖于温度的。这种新模型在基于连续体的有限元模拟中实现了金属的三种状态，包括粉末、液体和固体相。此外，它可以细致地模拟多层样品，以评估热力学性能和层间残余应力。首先，重新研究了基准问题，验证了该模型在预测瞬态温度分布和残余应力积累方面的准确性。然后，在单道三层测试箱上进行了热力学分析，研究了不同激光功率和扫描速度下IN718和ODS-IN718样品的L-PBF过程。同时，对ODS-IN718样品进行了热表征实验。结果表明，数值计算的熔池尺寸与实验结果吻合较好，平均误差为17%。此外，力学结果表明，高拉伸残余应力集中在轨道中部。基于不同激光扫描速度下不同层位应力分布的变化，对IN718和ODS-IN718样品的制造质量进行了综合比较。同时，通过优化激光扫描速度，使ODS-IN718合金的残余应力最小。总体而言，ODS-IN718具有比IN718更低的残余应力，特别是在较低的激光扫描速度下，这是由于分散颗粒的存在导致材料性能发生变化，从而增强了热机械行为。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Continuum Mechanics and Thermodynamics 物理-力学

CiteScore

5.30

自引率

15.40%

发文量

审稿时长

>12 weeks

期刊介绍： This interdisciplinary journal provides a forum for presenting new ideas in continuum and quasi-continuum modeling of systems with a large number of degrees of freedom and sufficient complexity to require thermodynamic closure. Major emphasis is placed on papers attempting to bridge the gap between discrete and continuum approaches as well as micro- and macro-scales, by means of homogenization, statistical averaging and other mathematical tools aimed at the judicial elimination of small time and length scales. The journal is particularly interested in contributions focusing on a simultaneous description of complex systems at several disparate scales. Papers presenting and explaining new experimental findings are highly encouraged. The journal welcomes numerical studies aimed at understanding the physical nature of the phenomena. Potential subjects range from boiling and turbulence to plasticity and earthquakes. Studies of fluids and solids with nonlinear and non-local interactions, multiple fields and multi-scale responses, nontrivial dissipative properties and complex dynamics are expected to have a strong presence in the pages of the journal. An incomplete list of featured topics includes: active solids and liquids, nano-scale effects and molecular structure of materials, singularities in fluid and solid mechanics, polymers, elastomers and liquid crystals, rheology, cavitation and fracture, hysteresis and friction, mechanics of solid and liquid phase transformations, composite, porous and granular media, scaling in statics and dynamics, large scale processes and geomechanics, stochastic aspects of mechanics. The journal would also like to attract papers addressing the very foundations of thermodynamics and kinetics of continuum processes. Of special interest are contributions to the emerging areas of biophysics and biomechanics of cells, bones and tissues leading to new continuum and thermodynamical models.